Diaper with separator sheet

ABSTRACT

Diapers, including infant diapers, training pants, and adult incontinence articles, and the like having a transverse separator sheet for excrement separation and/or isolation away from the skin with a specific design of attachment of the transverse separator sheet to the topsheet and to the elastic cuffs of the diapers.

FIELD OF THE INVENTION

This invention is directed to diapers, including infant diapers,including training pants, and adult incontinence articles, and the likehaving a specific transverse separator sheet for excrement separationand/or isolation away from the skin

BACKGROUND OF THE INVENTION

Several diaper types have been proposed with components to reduceleakage of feces and urine from the diaper, to reduce soiling of thegenitals or other skin by the feces, or to reduce mixing of urine andfeces, to further reduce the risk of irritation of the skin. Forexample, diapers with a topsheet with an opening, providing a passagewayto a void space for collected feces and urine have been proposed; alsoproposed are diapers with two openings to receive the urine and feces inseparate areas; also proposed are diapers with a transversely positionedthree-dimensional resilient barrier wall or partition placed in thecentre of the diaper, to receive feces and urine respectively on eitherside of said wall or partition, and to avoid migration of the feces tothe front of the article, beyond the separator, or combinations of theabove solutions. An example of such a topsheet structure withlongitudinal elasticated portions and a transverse portion with apartition is described in for example U.S. Pat. No. 7,918,838; however,such large structures may add significant cost to the product.Furthermore, if the central partition portion is too large, there is arisk that, upon misplacement of the diaper, feces or urine is receivedon this portion.

Simpler transversely positioned partitions are for example described inEP 674499, which describes a transverse separator sheet attached to thelongitudinal cuffs and to the topsheet of a diaper. The inventors foundhowever that the design of the attachments areas to both the cuffs andthe topsheet of such a transverse separator sheet may have a negativeimpact on the comfort, fit and absorbency properties of diaperscomprising such a transverse separator sheet.

Therefore, the present invention provides a diaper with a specificdesign for both the cuff attachment areas and the topsheet attachmentarea(s) which has a limited impact on the comfort, tit and absorbencyproperties of the diaper.

SUMMARY OF THE INVENTION

The invention relates to an infant or adult diaper having a longitudinalcenterline and a lateral centerline perpendicular to the longitudinalcenterline. The diaper comprises a topsheet and a backsheet andpositioned therein between an absorbent core, and a first and secondlongitudinally extending opposing elastic cuffs, positioned on eitherlongitudinal side of the topsheet. The diaper has a crotch region,positioned in between a front region and a back region. The diapercomprises a transverse separator sheet made of a separator sheetmaterial. The transverse separator sheet has a transversely extendingtop edge and top edge portion and an opposing transversely extendingbottom edge and bottom edge portion. Parts of the top edge portion areattached to the cuffs in the crotch region or front region of the diaperthereof by means of attaching a first attachment area of the top edgeportion to the first cuff in the crotch region or front region of thediaper and a second opposing attachment area of the top edge portion tothe second cuff in the crotch region or front region of the diaper, toform a first cuff attachment area and a second cuff attachment area.Each cuff attachment area has an inner edge towards the longitudinalcenterline of the diaper. Part(s) or all of the bottom edge portion areattached to the topsheet with one or more topsheet attachment area(s).The first cuff attachment area has a first projected bond length asmeasured according to the projected bond measurement test method and thesecond cuff attachment area has a second projected bond length asmeasured according to the projected bond measurement test method. Theaverage of the first and second projected bond lengths is from 1% to 20%or from 2% to 15% of the longitudinal dimension of the crotch region (B)of the diaper (1).

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a top view of a diaper according to an embodiment of thepresent invention in flat state.

FIG. 2 shows a perspective view of the diaper of FIG. 1.

FIG. 3 shows a top view of a diaper according to another embodiment ofthe present invention in flat state.

FIG. 4 shows a perspective view of the diaper of FIG. 3.

FIG. 5 shows a cross-sectional view of the diaper of FIG. 2 taken at thesection tine 2-2.

FIG. 6 shows a top view of the transverse separator sheet of FIG. 1 toillustrate how the projected bond lengths of cuff attachment areas ismeasured.

FIG. 7 shows a top view of the transverse separator sheet of FIG. 3 toillustrate how the projected bond lengths of a cuff attachment areas ismeasured.

FIG. 8 shows a top view of a transverse separator sheet according toanother embodiment of the present invention wherein the cuff attachmentareas are not mirror images from one another in the longitudinalcenterline of the diaper in fiat state of the diaper to illustrate howthe projected bond lengths of cuff attachment areas is measured

DETAILED DESCRIPTION OF THE INVENTION

“Diaper” is used herein, to refer to absorbent articles to be placedabout the wearer's lower torso, and include infant (baby and toddler)diapers and adult diapers, and it includes so-called diapers withfasteners, to be fastened around the lower torso, and pant-type diapers.

“Front region” (A) and ‘back region’ (C) are used herein to refer to thetwo regions of the diaper, which are in use, respectively, the closestto the front of the wearer and the back of the wearer, each spanning thetransverse dimension of the diaper, and each having a longitudinaldimension that is one third of the longitudinal dimension of the diaper.

“Crotch region” is used herein to refer to the region of the diaperwhich is positioned between the front region and the back region, havingalso a longitudinal dimension that is one third of the longitudinaldimension of the diaper.

For embodiments, wherein the front edge and/or back edge of the diaperis/are not configured as a straight line extending parallel to thetransverse centerline (X) of the diaper, the longitudinal dimension ofthe diaper corresponds to the longitudinal dimension measured betweenthe transverse line extending parallel to the transverse centerline (X)of the diaper and passing through the point of the front edge of thediaper which is closest to the transverse centerline (X) of the diaperand the transverse line extending parallel to the transverse centerline(X) of the diaper and passing through the point of the back edge of thediaper which is closest to the transverse centerline (X) of the diaper.For such embodiments, the longitudinal dimension of the front region orthe back region is measured starting from respectively the transverseline extending parallel to the transverse centerline (X) of the diaperand passing through the point of the front edge of the diaper which isclosest to the transverse centerline (X) of the diaper or the transverseline extending parallel to the transverse centerline (X) of the diaperand passing through the point of the back edge of the diaper which isclosest to the transverse centerline (X) of the diaper.

“Longitudinal” is used herein to refer to the direction which is runningsubstantially parallel or exactly parallel to the longitudinalcenterline (Y) of the diaper or topsheet, which may be the machinedirection (MD) of the process.

“Lateral” or “transverse” is used herein to refer to the direction whichis substantially perpendicular or exactly perpendicular to thelongitudinal centerline (Y) of the diaper or topsheet, which may be thecross-machine direction of the process (CD).

“Z-direction” is used herein to refer to the direction perpendicular tothe longitudinal direction and perpendicular to the transverse orlateral direction.

“Longitudinal dimension”, “transverse dimension” or “Z-dimension” isused herein to refer to the dimension of the diaper or element thereof,e.g. elastic cuff or topsheet or transverse separator sheet ortransverse separator sheet material or region of the diaper, which ismeasured respectively in the longitudinal direction, transversedirection or Z-direction of the diaper or element thereof, e.g. elasticcuff or topsheet or transverse separator sheet or transverse separatorsheet material or region of the diaper.

“Substantially perpendicular” or “substantially parallel” is used hereinto refer to directions within 30° or 20° or 10° or 5° from the exactperpendicular or parallel direction, unless stated or specifiedotherwise.

As used herein, “along” means ‘at least partially substantially parallelto and adjacent to’.

“Top edge” or “top edge portion” is used herein to refer to respectivelythe transversely extending edge or transversely extending edge portionof the separator sheet 10 or separator sheet material which is incontact with the wearer's body when the diaper 1 is applied to a wearer.

“Bottom edge” or “bottom edge portion” is used herein to refer torespectively the transversely extending edge or transversely extendingedge portion of the separator sheet 10 or separator sheet material 15which is more remote from the wearer's body (compared to the top edge ortop edge portion) when the diaper 1 is applied to a wearer.

“Relaxed” or “relaxed state” or “contracted” or “contracted state” isused herein to refer to the state of the diaper or separator sheet orseparator sheet material wherein no forces are applied to respectivelythe diaper or separator sheet or separator sheet material.

“Flat state” is used herein to refer to the state of the diaper when thediaper is laid out flat onto an even horizontal surface.

“Distal edge” is used herein to refer to the longitudinally extendingedge of an elastic cuff which in use is closer to the wearer's body thanthe other longitudinally extending edge of the same elastic cuff.

“Maximum transverse dimension of the one or more topsheet attachmentarea(s)” is used herein to refer to the transverse dimension of thetopsheet attachment area(s) which is measured between the two points ofthe topsheet attachment area(s) which are the most distant from eachother including gaps between two attachment areas in case there is morethan one topsheet attachment area, in flat state of the diaper 1.

“Minimum transverse dimension between the longitudinally extendingdistal edges of the first and second elastic cuffs” is used herein torefer to the minimum transverse dimension which is measured between thelongitudinally extending distal edges of the first and second elasticcuffs, in flat state of the diaper with the first and second cuffattachment areas being detached from the first and second elastic cuffs.

“Strain” is used herein to refer to the engineering strain which isdefined hereinafter in the test methods section of this application.

“Apertured topsheet” is used herein to refer to a topsheet whichcomprises at least one effective aperture.

“Effective aperture” is used herein to refer to any hole through atopsheet having a gray level less than or equal to 18 on a standard greylevel scale of 0-255 under image acquisition parameters described in thetopsheet effective aperture size and percentage open area measurementtest method.

“Effective aperture pattern density” is used herein to refer thepercentage of the surface area of an apertured topsheet which is coveredwith effective apertures.

“Bonding pattern density” is used herein to refer to the percentage ofthe surface area of a cuff attachment area or a topsheet attachment areawhich is covered with the one or more individual bond(s) which arecomprised by the cuff attachment area or the topsheet attachment area.

The diaper 1 according to the present invention has a longitudinalcenterline Y and a lateral centerline X perpendicular to thelongitudinal centerline Y. The diaper 1 comprises a topsheet 20, abacksheet 21 and positioned therein between an absorbent core 22. Thediaper 1 further comprises a pair of longitudinally extending opposingelastic cuffs 30 a, 30 b positioned on either longitudinal side of thetopsheet 20. The diaper 1 has a crotch region B positioned in between afront region A and a back region C.

The diaper 1 comprises a transverse separator sheet 10 made of aseparator sheet material 15 as for example shown in FIGS. 1 to 8.

Transverse Separator Sheet

The transverse separator sheet 10 herein is an individual sheet that isattached to a pair of opposing elastic cuffs 30 a, 30 b and to atopsheet 20. The separator sheet 10 prior to attachment to the cuffs 30a, 30 b or topsheet 20 is herein referred to as separator sheet material15. The separator sheet material 15 may be cut from a separator sheetmaterial web.

The separator sheet 10 may be present in the front region A and/orcrotch region B of the diaper 1; if present in the front region A of thediaper 1, it is in close proximity to the crotch region B, in the backhalf of the front region A of the diaper 1. For example, the minimumdistance between the topsheet attachment area(s) 14 and the front edge1F of the topsheet 20 or diaper 1 may be from 20%, or 25%, or 30% to60%, or to 50% or to 40% of the average longitudinal dimension (averagelength) of the topsheet 20 or diaper 1, respectively.

The separator sheet 10 and separator sheet material 15 have first andsecond transversely extending, opposing, edges and edge portions, hereinreferred to as a top edge 11 and top edge portion 16, and as a bottomedge 12 and bottom edge portion 17. The top edge 11 and bottom edge 12are connected to one another by two opposing side edges of the separatorsheet 10 or separator sheet material 15. It should be understood thatthe two opposing side edges of the separator sheet material 15 whichconnect the top edge 11 to the bottom edge 12 of the separator sheetmaterial 15 may be substantially perpendicular to the top edge 11 of theseparator sheet material, when the separator sheet material 15 is laidout flat in relaxed, contracted state onto an even horizontal surface.It should also be understood that some portions of the two opposing sideedges of the separator sheet 10 which connect the top edge 11 to thebottom edge 12 of the separator sheet 10 may have in use a Z-directionorientation.

The separator sheet material 15 may have when laid out flat onto an evenhorizontal surface in relaxed, contracted state, a longitudinaldimension (length), also referred to as the separator sheet'slongitudinal dimension (length) in relaxed state of the separator sheet10 and the separator sheet material 15 may have when laid out flat ontoan even horizontal surface in relaxed, contracted state, a transversedimension (width), also referred to as the separator sheet's transversedimension (width) in relaxed state of the separator sheet 10. It shouldbe understood that the width of the separator sheet 10 or separatorsheet material 15 may be longer than the length of respectively theseparator sheet 10 or separator sheet material 15.

The separator sheet 10 may have a minimum longitudinal dimension inrelaxed state of the separator sheet 10 between the top edge 11 and thebottom edge 12 of the separator sheet 10 of from 3.0 cm, or from 4.0 cm,or from 5.0 cm, to for example 15.0 cm or to 10.0 cm or to 8.0 cm or to7.0 cm, or to 6.0 cm or to 5.1 cm.

The separator sheet 10 may have an average transverse dimension inrelaxed state of the separator sheet 10 of at least 2.5 cm, or at least4.0 cm, or at least 5.0 cm to less than 12.0 cm or less than 10.0 cm.

Attachment of the Separator Sheet to the Elastic Cuffs

Parts of the top edge portion 16 of the separator sheet 10 are attachedto the elastic cuffs 30 a, 30 b in the crotch region B or front region Aof the diaper 1 thereof. A first cuff attachment area 13 a and a secondcuff attachment area 13 b are formed by attaching respectively a firstattachment area of the top edge portion 16 to the first cuff 30 a in thecrotch region B or front region A of the diaper 1 and a second opposingattachment area of the top edge portion 16 to the second cuff 30 b inthe crotch region B or front region A of the diaper 1. Each of the firstand second cuff attachment areas 13 a, 13 b has an inner attachment areaedge 131 a, 131 b which is the edge of attachment area 13 a, 13 b whichis the closest to the longitudinal centerline Y of the topsheet 20 ordiaper 1. Thus, there is a (central) part of the top edge portion 16which is not attached to either of the cuffs 30 a, 30 b. The minimumtransverse dimension of this (central) part of the separator sheet 10 inrelaxed, contracted state of the separator sheet 10, i.e. the separatorsheet's minimum transverse dimension of the separator sheet 10 inrelaxed state of the separator sheet 10 measured between the opposinginner attachment area edges 131 a, 131 b may be at least 20 mm, or atleast 30 mm. It may be up to 60 mm, or up to 55 mm or up to 50 mm or upto 45 mm.

The first cuff attachment area 13 a has a first projected bond lengthD_(4a), as measured according to the projected bond measurement testmethod and the second cuff attachment area 13 b has a second projectedbong length D_(4b), as measured according to the projected bondmeasurement test method. The average of the first and second projectedbond length D_(4a), D_(4b) may be from 1% to 20% or from 2% to 15% ofthe longitudinal dimension of the crotch region (B) of the diaper (1).The average of the first and second projected bond length D_(4a), D_(4b)may be from 3 mm to 25 mm or from 5 mm to 15 mm. This ensures that thetop edge portion 16 which is in contact with the wearer's body is longenough to not create pressure marks on the wearer's skin when the diaperis applied to a wearer but not too long to avoid covering of theurination point and/or the anus point which would very likely reduce theabsorbency properties of the diaper 1.

Each of the first and second elastic cuffs 30 a, 30 b has alongitudinally extending distal edge 301 a, 301 b. The minimumtransverse dimension between the longitudinally extending distal edge ofthe first elastic cuff 301 a and the inner attachment area edge of thefirst cuff attachment area 131 a and/or the minimum transverse dimensionbetween the longitudinally extending distal edge of the second elasticcuff 301 b and the inner attachment area edge of the second cuffattachment area 131 b is of 0 to 15 mm or 0 to 5 mm. Such aconfiguration is particularly advantageous in order to reduce the riskof migration of the feces above the transverse separator sheet 10 whenthe diaper 1 is loaded with bodily exudates.

The first and second cuff attachment areas 13 a, 13 b may be mirrorimages of one another in the longitudinal axis Y of the diaper 1, inflat state of the diaper 1 as for example shown in FIGS. 1 to 8.

The first and second cuff attachment areas 13 a, 13 b may have anyshape. They may have a rectangular shape as shown for example in FIGS. 1to 8. They may also have a round or an oval shape.

The inner edge(s) of the first and/or second cuff attachment area(s) 131a, 131 b may be oriented parallel to the longitudinal centerline Y ofthe diaper 1 in flat state of the diaper 1, as for example shown inFIGS. 1, 2, 5 and 6.

The inner edge(s) of the first and/or second cuff attachment area(s) 131a, 131 b may form an angle α_(a), α_(b) of more than 0° to less than 90°or of 15° to 70°, or 30° to 60°, or 40° to 50° with a longitudinal lineparallel to the longitudinal centerline Y of the diaper 1, in flat stateof the diaper 1 as for example shown in FIGS. 3, 4, 7 and 8. Such aconfiguration is particularly advantageous since it is possible toprovide the transverse separator sheet 10 with a longer and thereforestronger cuff attachment area 13 a, 13 b without considerably increasingthe projected bond lengths of the first and second cuff attachment areasD4_(a), D4_(b).

It should be understood that a non straight inner edge 131 a, 131 b isconsidered as being oriented parallel to the longitudinal centerline Yof the diaper 1 or as forming an angle α_(a), α_(b) of more than 0° witha longitudinal line parallel to the longitudinal centerline Y of thediaper 1 if the inner edge of the rectangle with the smallest areapossible surrounding the cuff attachment area 13 a, 13 b is respectivelyoriented parallel to the longitudinal centerline Y of the diaper 1 orforming an angle α_(a), α_(b) of more than 0° with a longitudinal lineparallel to the longitudinal centerline Y of the diaper 1, in flat stateof the diaper 1. It should also be understood that a round shaped cuffattachment area 13 a, 13 b is considered as being parallel to thelongitudinal centerline Y of the diaper 1, in fiat state of the diaper1.

One separator sheet's minimum transverse dimension D₅ in relaxed stateof the separator sheet 10 between the opposing inner edges 131 a, 131 bof the first and second cuff attachment areas 13 a, 13 b may closer tothe top edge 11 of the separator sheet 10 than one separator sheet'smaximum transverse dimension D₆ in relaxed state of the separator sheet10 between the opposing inner edges 131 a, 131 b of the first and secondcuff attachment areas 13 a, 13 b as for example shown in FIG. 3.

Each cuff attachment area 13 may have an average transverse dimension of3% to 40% or 5% to 35% or 5% to 25% of the average transverse dimensionof the separator sheet 10.

The attachment of the separator sheet 10 to the elastic cuffs 30 a, 30 bcan be done by adhesive bonding, pressure bonding, ultrasonic bonding orany other attachment mean known in the art. A cuff attachment area 13may comprise one or more individual bond(s). Such individual bond(s) maybe arranged according to a certain bonding pattern.

It should be understood that if a cuff attachment area 13 comprises morethan one individual bond, these are herein considered as a singleunitary cuff attachment area.

The bonding pattern density of the first and/or second cuff attachmentarea(s) 13 a, 13 b may be more than 20%, or more than 30%, or more than40%, or more than 60%, up to 100%.

Attachment of the Separator Sheet to the Topsheet

Part(s) or all of the bottom edge portion 17 of the separator sheet 10is/are attached to the topsheet 20 with one or more topsheet attachmentarea(s) 14. This may be in the front region A or crotch region B of thediaper 1 or topsheet 20.

Each of the one or more topsheet attachment area(s) 14 may have amaximum longitudinal dimension of from 1% to 10% or from 1% to 6% of thelongitudinal dimension of the crotch region (B) of the diaper (1). Eachof the one or more topsheet attachment area(s) 14 may have a maximumlongitudinal dimension of from 1 mm to 15 mm or from 2 mm to 10 mm. Thisis particularly advantageous since it ensures that the bottom edgeportion 17 of the separator sheet 10 is not too long and therefore doesnot cover a substantial portion of the topsheet which may very likelyreduce the absorbency properties of the diaper 1.

The topsheet attachment area(s) 14 may comprise one central topsheetattachment area 14 a and two side topsheet attachment areas 14 b, 14 con either side of the central topsheet attachment area 14 a, as forexample shown in FIGS. 1 to 8. This is particularly advantageous inorder to ensure that the separator sheet 10 is correctly anchored to thetopsheet 20 without increasing the stiffness of the diaper 1 to anextent that the diaper 1 becomes less comfortable for the wearer.

As mentioned hereinbefore, each of the first and second elastic cuffs 30a, 30 b has a longitudinally extending distal edge 301 a, 301 b. Themaximum transverse dimension D₇ of the one or more topsheet attachmentarea(s) 14 may be centered on the longitudinal centerline Y of thediaper 1 in flat state of the diaper 1 as for example shown in FIG. 1.Such a configuration helps to prevent in-use skewed separator sheet 10which may cover the urination and/or the anus point or may inadvertentlycreate gaps between the elastic cuffs 30 a, 30 b and the skin of thewearer, when the diaper 1 is applied to the wearer, gaps which may beresponsible of leakage of bodily exudates in in-use conditions.

The maximum transverse dimension D₇ of the one or more topsheetattachment area(s) 14 may be comprised within the minimum transversedimension D₈ between the longitudinally extending distal edges of thefirst and second elastic cuffs 301 a, 301 b, in flat state of the diaper1 as for example shown in FIG. 1. The maximum transverse dimension D₇ ofthe one or more topsheet attachment area(s) 14 may be of 50% to 98% or60% to 95% of the minimum transverse dimension D₈ between thelongitudinally extending distal edges of the first and second elasticcuffs 301 a, 301 b, in flat state of the diaper 1. In such aconfiguration, the topsheet attachment area(s) 14 is/are thereforecompletely comprised between the first and second elastic cuffs 30 a, 30b. This is particularly advantageous in order to reduce the risk thatthe distal edges of the elastic cuffs 301 a, 301 b may be inadvertentlyattached to the topsheet 20 when the separator sheet 10 is attached tothe topsheet 20 during manufacturing of the diaper 1 which may beresponsible for leakage of bodily exudates around the leg openings whenthe diaper 1 is applied to a wearer.

The topsheet attachment area(s) 14 may have any shape. They may have arectangular shape as for example shown in FIGS. 1 to 8. Such rectangularshaped topsheet attachment areas 14 may be oriented parallel to thelongitudinal centerline Y of the diaper 1, in flat state of the diaper1. They may also have a round or an oval shape.

The attachment of the separator sheet 10 to topsheet 20 can be done byadhesive bonding, pressure bonding, ultrasonic bonding or any otherattachment mean known in the art. The topsheet attachment area(s) 14 maycomprise one or more individual bond(s). Such individual band(s) may bearranged according to a certain bonding pattern.

It should be understood that if a topsheet attachment area 14 comprisesmore than one individual bond with a shortest distance of less than 3 mmbetween them, these are herein considered as a single unitary topsheetattachment area.

The bonding pattern density of at least one of (or each of) the topsheetattachment area(s) 14 may be more than 20%, or more than 30%, or morethan 40%, or more than 60%, up to 100%.

The topsheet 20 may be an apertured topsheet which comprise apertures toallow urine to pass to the absorbent core 22 under the topsheet 20.

In embodiments wherein the topsheet 20 is an apertured topsheet, each ofthe one or more topsheet attachment area(s) 14 may comprise one or moreindividual bond(s), wherein the at least one of (or each of) thetopsheet attachment areas 14 have a bonding pattern density which ishigher than the percentage open area of the topsheet 20 measuredaccording to the topsheet effective aperture size and percentage openarea measurement test method. In such embodiments, at least one of (or50% or more or each of) the individual bonds of at least one of (or eachof) the topsheet attachment areas 14 may have a bigger size than atleast one of (or 50% or more or each of) the effective apertures of thetopsheet 20. In such embodiments, the bonding pattern of at least one of(or each of) the topsheet attachment areas 14 may not overlap with theeffective aperture pattern of the topsheet 20 if the individual bond(s)comprised by the topsheet attachment area(s) 14 have the same size or asmaller size than the effective apertures of the topsheet 20. Theseconfigurations are particularly advantageous in order to ensure a goodanchorage of the separator sheet 10 to the topsheet 20.

The separator sheet 10 has a first side 101 and a second side 102. Thefirst side 101 may be attached to both the elastic cuffs (30 a, 30 b)and the topsheet 20. Alternatively, the first side 101 may be attachedto the elastic cuffs 30 and the second side 102 to the topsheet 20, asfor example shown in FIGS. 1 to 5.

The topsheet attachment area(s) may be positioned closer to the frontedge 1F of the diaper 1, or topsheet 20 or backsheet 21 than the cuffattachment areas 13 a, 13 b, as for example shown in FIGS. 1 to 5. Thismay reduce the risk that the separator sheet 10 creates a ramp whichfacilitates the migration of the feces to the front of the diaper 1.

Transverse Separator Sheet Material

The separator sheet 10 may be elastically extensible in at least thetransverse direction, i.e. is able to extend upon application of aforce, and to contract to about its original width upon release of saidforce, as described hereinafter. Only the top edge portion 16 of theseparator sheet 10 may be elastically extensible in at least thetransverse direction.

The separator sheet 10 may also be elastically extensible in thelongitudinal direction.

The separator sheet 10 may be made of an elasticated sheet material 15,rendering the separator sheet 10 elastically extensible in thetransverse direction at least. “Elasticated” when used herein for theseparator sheet 10 or separator sheet material 15 (and also for the cuffor cuff web material) means that it is made of an inelastic sheetmaterial that has been provided only in a specific area or in specificareas, i.e. the elasticated area(s), with an elastic material, e.g. oneor more elastic bands or strands. The total surface area of theelasticated areas may for example be less than 50% of the total surfacearea of the separator sheet 10 or separator sheet material 15.

One or both of the top and bottom edge portions 16, 17 of the separatorsheet 10 or separator sheet material 15 may be elasticated byapplication of one or more elastic band(s) or strand(s) extendingsubstantially in transverse direction to a sheet material that may beinelastic e.g. an inelastic nonwoven sheet.

The separator sheet 10 may be elastically extensible in transversedirection at least. It may be elastically extensible in transversedirection at least over its surface area excluding the surface areasthat are attached to the cuffs 30 a, 30 b and topsheet 20.

The separator sheet material 15 may be or may comprise an elastic filmor a nonwoven sheet material or a laminate of an elastic film and anonwoven sheet material. The nonwoven sheet material of the laminate canbe positioned such that it is in contact with the skin of the wearer.Such a configuration of the laminate may provide more comfort to thewearer than when the elastic film is directly in contact with the skinof the wearer.

The nonwoven sheet material may be made of polyolefins known in the art,such as polyethylene and/or polypropylene, made into fibers, includingbicomponent fibers that are then made into a nonwoven sheet. Thenonwoven sheet material may be a necked nonwoven. The nonwoven sheetmaterial may be a meltblown nonwoven or spunbond nonwoven or cardednonwoven; it may be a laminate thereof; for example it may be a laminateof spunbond or carded layer or layers and meltblown nonwoven layer(s).

The separator sheet material 15 may be or comprise a nonwoven sheetmaterial that has a substantially uniform elastic behavior due to theapplication (e.g. substantially uniformly) of an elastic material to thenonwoven sheet material, in a way that it provides elasticity at leastin transverse direction to the nonwoven sheet material; for example,elastic material may be sprayed or extruded onto a nonwoven sheetmaterial, e.g. homogeneously or in a pattern such as stripes intransverse direction.

The separator sheet material 15 may be rectangular or square when laidout flat in relaxed, contracted state onto an even horizontal surface inrelaxed, contracted state. The separator sheet material 15 may also betrapezoid when laid out flat in relaxed, contracted state onto an evenhorizontal surface in relaxed, contracted state, the top edge 11 and thebottom edge 12 of the separator sheet material 15 forming the twoparallel sides of the trapezoid.

The separator sheet material 15 may be a harrier material; it may behydrophobic; e.g. it may be hydrophilic and made hydrophobic with ahydrophobic surface coating, such as known in the art, for example a waxor a hydrophobic surface coating comprising one or more siliconepolymers or fluorinated polymers.

The separator sheet 10 has an elastic behavior such that it can besignificantly elastically extensible in transverse direction at least,during the process of making the diaper 1, and during application of thediaper 1 on the wearer, whilst providing in in-use conditions (duringwear) correct alignment with the skin of the wearer, both when thewearer moves the legs apart and when the wearer moves the legs together.The separator sheet 10 should furthermore preferably have a certaintension in use to ensure it forms an effective separator (barrier) witha Z-direction dimension, to avoid migration of feces from the back tothe front of the diaper 1. Furthermore, this tension should not be toohigh, otherwise the cuffs 30 a, 30 b, to which the separator sheet 10 isattached, are in use pulled too close together, leading to potentialleakage issues of urine or feces outside or onto the cuffs 30 a, 30 b.

The separator sheet 10 may be elastically extensible in the transversedirection to a strain of at least 0.8, as measured according to thein-process two-cycle hysteresis test. The separator sheet 10 orseparator sheet material 15 may be elastically extensible in thetransverse direction to a strain of at least 1.2 or at least 1.5 or atleast 2.0 or at least 2.5 or at least 3.0 or at least 3.5, as measuredaccording to the in-process two-cycle hysteresis test. This can be donewith any force suitable for processing elastic materials, typically aforce of 20 N or less, or typically a force of 10N or less. Therefore,the separator sheet 10 is such that it can be processed in a processthat requires high extension, and that it contracts about immediately toabout its original width, to allow high speed of processing.

It should be understood that the separator sheet 10 is considered asbeing elastically extensible in the transverse direction to a certainstrain value if after having been extended to said strain valueaccording to the in-process two-cycle hysteresis test, the percent setmeasured according to the in-process two-cycle hysteresis test is of 30%set or less or 20% or less or 10% or less. Having such a low set valueensures that the separator sheet material 15 is not damaged duringprocessing of the diaper 1.

Cuffs

The diaper 1 has a pair of first and second longitudinally extendingopposing elastic cuffs 30 a, 30 b, to which the separator sheet 10(material 15) is attached.

Each of the cuffs 30 a, 30 b to which the separator sheet 10 is attachedmay be part of a unitary dual cuff sheet, comprising an outer cuff (legcuff) and an inner cuff (barrier cuff), the latter being attached to theseparator sheet 10.

Each cuff 30 a, 30 b has a longitudinally extending proximal edge thatis joined to or attached to a diaper element, e.g. to the backsheet 21or topsheet 20, or leg cuff, if present and an opposing, longitudinallyextending, distal edge that is in use in contact with the skin of thewearer.

The cuffs 30 a, 30 b may be attached to the backsheet 21 adjacent andalong the longitudinal sides of the backsheet 21 to have a cuff 30 a, 30b on either side of the backsheet 21. The cuffs 30 a, 30 b may beattached to the topsheet 20, adjacent and along the longitudinal sidesof the topsheet 20 to have a cuff 30 a, 30 b on either side of thetopsheet 20.

The cuffs 30 a, 30 b may be mirror images of one another in thelongitudinal centerline Y of the diaper 1, in flat state of the diaper1. Each cuff 30 a, 30 b and/or its proximal edge may be curved or may besubstantially straight.

The cuffs 30 a, 30 b may be made from a pair of cuff webs, comprisingeach multitude of cuffs which are then separated from one another toform individual cuffs.

The cuffs 30 a, 30 b are elastic or elasticated, for example asdescribed above with respect to the separator sheet 10 or separatorsheet material 15. The cuffs 30 a, 30 b may be at least, or only,elasticated along the distal edge thereof. Each cuff 30 a, 30 b may be asheet material with one or more elastic strands attached thereto instretched state. The one or more elastic strands may extend at leastalong the distal edge of the cuff 301 a, 301 b.

The proximal edge of each cuff 30 a, 30 b may be positioned along alongitudinal side of the absorbent core 22 or of the backsheet 21 or ofthe topsheet 20.

The proximal edge of each cuff 30 a, 30 b may be positionedlongitudinally outwards of the absorbent core 22, so that the wholeabsorbent core 22 is in between the cuffs proximal edges.

The cuffs 30 a, 30 b may be attached such that in use they haveZ-direction orientation.

Each of the cuffs' distal edges 301 a, 301 b may be further attached inthe back edge 1B (e.g. waistband) and/or front (e.g. waistband) edge 1Fof the diaper 1, or the topsheet 20 or backsheet 21 in respectivelyso-called front 35 a, 35 b and back 34 a, 34 b tack-down zones as forexample shown in FIGS. 1 and 3.

The transverse distance between the front tackdown zone 35 a of thefirst cuff 30 a and the front tackdown zone 35 b of the opposing secondcuff 30 b may equal the maximum transverse distance between the cuffsdistal edges 301 a, 301 b in flat state of the diaper 1. This transversedistance may be at least 5.0 cm, or at least 6.0 cm, or at least 7.0 cm.This transverse distance may be up to the average transverse dimensionof the diaper 1 measured in the crotch region of the diaper 1, in flatstate of the diaper 1. The same may apply to the transverse distancebetween the back tackdown zone 34 a of the first cuff 30 a and the backtackdown zone 34 b of the opposing second cuff 30 b.

Each cuff 30 a, 30 b may have an elastic tension of at least 20 grams(0.2N) and up to 100 grams (1.0N), or up to 50 grams (0.5N), whenextended to a 95% or 80% extension strain.

The cuffs 30 a, 30 b or cuff web material may comprise a nonwoven sheetmaterial. The same nonwoven sheet materials as the ones used to make thetransverse separator sheet 10 may be used. The nonwoven sheet materialmay be a nonwoven barrier sheet material that is liquid impermeable, asknown in the art, including for example nonwoven laminate(s) with one ormore spunbond layers and/or carded layers, and one or more meltblownlayers. The fibers used to form the nonwoven sheet material may beselected from polypropylene fibers, polyethylene fibers, bicomponentfibers, nano-fibers and any combinations thereof.

The cuffs 30 a, 30 b or part thereof, and/or the separator sheet 10 orpart thereof may comprise a skin care composition, e.g. lotion, as knownin the art.

The separator sheet 10 or separator sheet material 15 may be attached tothe cuffs 30 a, 30 b in relaxed, contracted state. The cuffs 30 a, 30 bmay then be spread apart, thereby stretching the separator sheet 10 orseparator sheet material 15.

The cuffs 30 a, 30 b may have any suitable dimensions, for exampledepending on the diaper-dimensions. They may extend about the fulllength of the diaper 1. They may have a transverse dimensionperpendicular to longitudinal centerline Y of the diaper 1 of forexample at least 30 mm, or for example at least 40 mm.

Topsheet

The diaper 1 comprises a topsheet 20. The topsheet of the diaper 1herein may be made of any suitable material known in the art, providedit allows urine to pass. Hereto, it may be made of a urine permeablematerial, including hydrophilic material, or material treated to behydrophilic. As explained hereinbefore, the topsheet 20 may be anapertured topsheet which comprise apertures to allow urine to pass tothe absorbent core 22 under the topsheet 20. The topsheet 20 maycomprise apertures with an effective aperture size of at least 0.2square millimeters or at least 0.3 square millimeters as measuredaccording to the topsheet effective aperture size and percentage openarea measurement test method.

The topsheet may be either hydrophilic or hydrophobic.

The separator sheet 10 or separator sheet material 15 may be attached tothe cuffs 30 a, 30 b and to the topsheet 20 in relaxed, contractedstate. The cuffs 30 a, 30 b may then be spread apart, thereby stretchingthe separator sheet 10 or separator sheet material 15; the cuffs 30 a,30 b may for example be attached to the topsheet 20 prior to spreadingor subsequent to the spreading step.

The topsheet 20 may be a stretchable material, or a material that isextensible, for example by the provision of folds. The topsheet 20 mayfor example comprise one or more longitudinally extending Z-fold(s)prior to attachments to the separator sheet 10 (or separator sheetmaterial 15) and/or to the cuffs 30 a, 30 b. Once the topsheet 20 isunfolded, it no longer has the folds, e.g. fold(s), but it may stillhave the longitudinally extending fold lines.

Preferred topsheet materials are nonwoven materials, including laminatesand/or materials with apertures, such as apertured films, apertureformed films.

The topsheet 20, or for example only the crotch and/or back regionthereof, may comprise a skin care composition, e.g. a lotion.

Other Elements of the Diaper

The diaper 1 has also at least a backsheet 21 and an absorbent core 22,the absorbent core 22 comprising for example multiple layers, includingfor example one or more acquisition layers, in liquid communication withthe topsheet 20, and a storage layer, comprising superabsorbent polymermaterial/particles at least, typically enclosed by a core covermaterial.

The acquisition layer or layers may comprise any acquisition materialwhich is capable of acquiring urine or runny feces, such as comminutedwood pulp, creped cellulose wadding; melt blown polymers, includingcoform; chemically stiffened, modified or cross-linked cellulosicfibers; tissue, including tissue wraps and tissue laminates; absorbentfoams; absorbent sponges.

The storage layer may comprise any of the above material, but ittypically at least comprises superabsorbent polymericmaterial/particles; for example; the absorbent storage layer maycomprise more than 80% by weight (e.g. excluding core wrap) ofsuperabsorbent polymeric (particulate) material; it may be free ofcellulose (airfelt) material.

The backsheet 21 may be liquid impervious, as known in the art. Theliquid impervious backsheet 21 preferably comprises a thin plastic filmsuch as a thermoplastic film, for example having a thickness of about0.01 mm to about 0.05 mm. Suitable backsheet materials comprisetypically breathable material, which permit vapors to escape from thediaper 1 while still preventing exudates from passing through thebacksheet 21. Suitable backsheet films include those manufactured byTredegar Industries Inc. of Terre Haute, Ind. and sold under the tradenames X15306, X10962 and X10964.

The backsheet 21, or any portion thereof, may be elastically extendablein one or more directions. The backsheet 21 may be attached or joined toa topsheet 20, the absorbent core 22, or any other element of the diaper1 by any attachment means known in the art. It may be highly preferredthat the longitudinal side edges of the topsheet 20 and backsheet 21 aredirectly attached to one another.

The diaper 1 may also include a sub-layer disposed between the topsheet20 and the absorbent core 22, capable of accepting, and/or immobilizingbodily exudates, typically fecal material.

The diaper 1 herein may have a fastening system, typically joined to thewaistband, as known in the art. Preferred fastening systems comprisefastening tabs and landing zones, wherein the fastening tabs areattached or joined to the back region of the diaper 1 and the landingzones are part of the front region A of the diaper 1.

The diaper 1 may be a pant-type diaper that has fastened side portions.

Test Methods Projected Bond Measurement Test Method:

This method determines the projected bond length of a cuff attachmentarea. The diaper 1 is laid out flat onto an even horizontal surface. Afirst longitudinally extending line L₁ parallel to the longitudinalcenterline Y of the diaper 1 and in contact with the point of the cuffattachment area 13 which is the closest to the longitudinal centerline Yof the diaper 1 is drawn, as for example shown in FIGS. 6, 7 and 8. Asecond longitudinally extending L₂ parallel to the first longitudinallyextending line L₁ is drawn further away from the longitudinal centerlineY with a distance D₃ between the first and the second longitudinallyextending lines L₁, L₂ of 5 mm, as for example shown in FIGS. 6, 7 and8. A first laterally extending line L₃ perpendicular to the longitudinalcenterline Y of the diaper 1 and in contact with the point of the cuffattachment area 13 which is the closest to the front edge 1F of thediaper 1 and laterally comprised between the first and the secondlongitudinally extending lines L₁, L₂ is drawn, as for example shown inFIGS. 6, 7 and 8. A second laterally extending line L₄ perpendicular tothe longitudinal centerline Y of the diaper 1 and in contact with thepoint of the cuff attachment area 13 which is the closest to the backedge 1B of the diaper 1 and laterally comprised between the first andthe second longitudinally extending lines L₁, L₂ is drawn as for exampleshown in FIGS. 6, 7 and 8.

The distance D₄ between the first and second laterally extending linesL₃, L₄ corresponds to the projected bond length of the cuff attachmentarea 13.

In-Process Two Cycle Hysteresis Tests: Equipment and Preparation ofSamples:

Suitable instruments for this test include tensile testers commerciallyavailable from MTS Systems Corp., Eden Prairie, Minn. (e.g. AllianceRT/1 or Sintech 1/S) or from Instron Engineering Corp., Canton, Mass. orfrom Zwick/Roell, Kennesaw, Ga./Ulm, Germany.

The tester is equipped with a grip face set in the upper and lowergrips, where each set has one rubber-coated face (80 A shore hardness)and one contact line face (metal), with a screw mechanism that engagesthe contact line face into the rubber-coated face to prevent slippage.The length of the upper and lower grips is at least as long as theclamped length of the specimen to be tested, the grip length being thedimension of the grip parallel to the length of the specimen. A loadcell is used so that the maximum load measured is within 10-90% of themaximum capacity of the load cell. The instrument is calibratedaccording to the manufacturer's specification.

Before obtaining the specimen from the diaper, the diaper is kept in arelaxed state at ambient temperature (22° C. +/− 5° C.) for at least 24hours.

The separator sheet 10 is cut to obtain a rectangular specimen having atransverse dimension (width) of 20 mm centered on the longitudinalcenterline Y of the diaper 1 and a longitudinal dimension (length) of 30mm, both transverse and longitudinal dimensions being measured inrelaxed, contracted state when the specimen is laid out flat onto aneven horizontal surface. The transverse dimension and longitudinaldimension of the specimen are measured parallel to respectively thetransverse dimension and longitudinal dimension of the separator sheet10. The transversely extending edge of the specimen which is the closestto the top edge 11 of the separator sheet 10 is referred hereinafter asthe top edge of the specimen. The opposite transversely extending edgeof the specimen is referred hereinafter as the bottom edge of thespecimen.

For separator sheet(s) 10 that has/have a minimum length in relaxed,contracted state between the top edge and the bottom edge of more than30 mm, the specimen is cut such that it does include the top edge of theseparator sheet 10.

Clamped Length

The clamped length is the length of specimen in relaxed, contractedstate which is clamped between the grips starting from the top edge ofthe specimen. The clamped length is equal to the average of the firstand second projected bond lengths D4_(a), D4_(b). The first and secondprojected bond lengths D4_(a), D4_(b), are measured according to theprojected bond measurement test method prior to cutting of the testspecimen.

Before starting the test (details below), each specimen and theequipment must equilibrate at 22° C. (+/− 1° C.), for at least 1 hour,for the in-process two cycle hysteresis tests herein.

The force reading on the instrument is zeroed to account for the mass ofthe fixtures and grips. The specimen is mounted into the grips with noslack and the force measured is between 0.00 N and 0.01 N. The dataacquisition frequency is 100 Hz; the force, time and engineering straindata are acquired during all segments of the hysteresis tests.

The specimen is mounted with 10 mm of its width in relaxed, contractedstate between the lines of contact of the grips (gauge width) and 5 mmof its width outside the line of contact of each grip. The clampedlength of the specimen is clamped in the grips. The remaining length ofthe specimen (which equals the length of the specimen minus the clampedlength) is excluded from the grips. The clamped length is specifiedabove.

In the following, engineering strain is defined as ΔW/W₀ withΔW=W_(t)−W₀, wherein W₀ is the initial sample width and W_(t) is thesample width at time t.

In-Process Two-Cycle Hysteresis Test (Measurement at 22° C.):

The In-Process two-cycle hysteresis test is performed as follows:

1. Slack Adjustment:

Move the crosshead at a speed of 13 mm/minute until the slack adjustmentpreload force of 0.02 N is achieved. The distance between the lines ofcontact of the grips at the slack adjustment preload force of 0.02N isthe adjusted gauge width W_(GAdj) which is equal to the initial samplewidth W₀ (engineering strain=0%).

2. First Cycle:

The specimen is extended to the tested engineering strain at a crossheadspeed of 800 mm/min. There is no hold at this engineering strain. Thecrosshead is then returned to the adjusted gauge width W_(GAdj), at acrosshead speed of 800 mm/min, and held at this engineering strain for60 seconds.

3. Second Cycle:

The specimen is extended to the same engineering strain as theengineering strain in the first cycle, at a crosshead speed of 800mm/min. There is no hold at this engineering strain. The crosshead isthen returned to the adjusted gauge width W_(GAdj) at a crosshead speedof 800 mm/min and held at this engineering strain for 60 seconds.

Each specimen of separator sheet of the diaper is inspected for damageafter the In-Process two-cycle hysteresis test. Separator sheet materialof the invention must have no damage after the test, The damage isdefined via the percent set. The percent set (% Set) is defined as theengineering strain, in percent, where the 2^(nd) cycle extension forceof 0.069 N (7 gram-force) is measured. If the percent set is lower than30%, the specimen is considered as not being damaged and is thereforeconsidered as being elastically extensible to tested engineering strain.

A minimum of 5 specimens are measured, to determine the average testvalues, average data being provided by the tensile tester test software(e.g. Alliance RT1 MTS Instrument is TestWorks4 version 4.08 B)

The method report specifies the used engineering strain, the specimendimensions and the clamped length used for the measurements.

The property of the separator sheet reported for the method is the %set.

Topsheet Effective Aperture Size and Percentage Open Area MeasurementTest Method:

The effective aperture size and percentage open area are determined bythe following procedure using the image analysis system described below.The procedure has three principal steps: image acquisition, i.e.,obtaining representative images of areas on the surface of the topsheet;image measurement, i.e., measuring the percentage open area of an imageand of individual apertures and their perimeters; and data analysis,i.e., exporting the percentage open area, individual aperture area, andperimeter measurements to a spreadsheet where frequency distributions,sum of area distributions, and hydraulic radius computations are made.

An image analysis system having a frame grabber board, microscope,camera and image analysis software is utilized. A model DT2855 framegrabber board available from Data Translation of Marlboro, Mass. isprovided. A VH5900 monitor microscope, a video camera, having a VH50lens with a contact type illumination head available from the KeyenceCompany of Fair Lawn, N.J. are also provided and used to acquire animage to be saved to computer file. The Keyence microscope acquires theimage and the frame grabber board converts the analog signal of thisimage into computer readable digital format. The image is saved tocomputer file and measured using suitable software such as the OptimasImage Analysis software, version 3.1, available from the BioScan Companyof Edmonds, Wash. In order to use the Optimas Image Analysis software,the computer should have Windows software, version 3.0 or later,available from the Microsoft Corporation of Redmond, Wash. and also havea CPU at least equivalent to the Intel 80386. Any suitable desk top PCmay be used, with a 486 DX33 type PC having been found to beparticularly suitable. Images being saved to and recalled from file weredisplayed on a Sony Trinitron monitor model PVM-1343MO with a finaldisplay magnification of about 50×.

The image acquisition step, noted above requires 10 different regionsfrom a representative topsheet sample of a particular type of diaper orfrom sample material to be tested. Each region is rectangular, measuringabout 5.8 millimeters by 4.2 millimeters. The sample is placed on ablack mat board to increase the contrast between the apertures and theportion of the sample that defines the apertures. The mean gray leveland standard deviation of the black mat board were 16 and 4,respectively.

Images are acquired with room lights off using the Keyence monitormicroscope mounted on a copystand directly above the sample. The Keyencelight source illuminating the sample is adjusted and monitored with theOptimas software to measure the mean gray level and standard deviationof a 0.3 density wedge on a Kodak Gray Scale available from EastmanKodak Company of Rochester, N.Y. The control of Keyence light source isadjusted so that the mean gray level of the illuminated wedge is 111±1and the standard deviation is 10±1. All images were acquired during asingle time period, and the Keyence light source is monitored bymeasuring the mean gray level and standard deviation of the wedgethroughout the image acquisition process.

In measuring an individual aperture, only the effective aperture size isof interest. Measuring the effective aperture size quantifies theaperture size intended to contribute to the porosity of the topsheet,and account for contributions fibers and fiber bundles that traverse anarea intended to be an aperture. An effective aperture is any holethrough the topsheet having a gray level less than or equal to 18 usingimage acquisition parameters as described herein. Thus, an intendedaperture may be divided into plural effective apertures by traversefibers.

The image analysis software is calibrated millimeters by a ruler imageacquired from the sample images. A 3 by 3 pixel averaging filter foundin the Optimas 3.1 Image menu is applied to each saved image to reducenoise. The apertures are detected in the gray level range of 0 through18. An aperture that is not fully contained within the 5.8 by 4.2viewing area is not considered in the individual area and perimetermeasurements. Therefore, area and perimeter averages and distributionsare not affected by apertures that are not wholly contained within thefield of view.

However, individual apertures that could not be fully viewed in theimage are included in the percentage open area calculation. Thisdifference occurs because the percent open area is simply the image ofpixel ratios from 0 through 18 to the total number of pixels in theimage. Areas having a gray level 19 or greater were not counted in theopen area calculation.

The percentage open area for the average of 10 images for each topsheetis measured using the Optimas Image Analysis software. The percentageopen area is defined as the ratio of the number of pixels having a graylevel from 0 through 18 to the total number of pixels for the image. Thepercentage open area is measured for each image representing oneparticular region from a topsheet sample. The percentage open area fromeach of the 10 individual images is then averaged to yield a percentageopen area for the entire sample.

The data analysis is conducted by an Excel spreadsheet, also availablefrom the Microsoft Corporation of Redmond, Wash. The Excel spreadsheetorganized the percentage open area, aperture area, and apertureperimeter measurements obtained from the Optimas software. Sampleaverages and standard deviations, size and frequency distributions ofindividual aperture areas and hydraulic radius computations (areadivided by perimeter) for individual apertures are obtained using thespreadsheet.

Distributions of individual aperture area are also computed using theExcel spreadsheet. The apertures are sorted into bins of certain sizeranges. The number of aperture areas falling into certain size ranges ofinterest is determined as well as the sum of the areas within eachrange. The ranges are set in increments of 0.05 square millimeters.These areas are expressed as a percentage of the total open area of thesample. The frequency and sum of the area distributions are obtained bycombining individual aperture measurements from all 10 images for eachsample.

EXAMPLES

Four different diapers comprising a transverse separator sheet areprepared. Each of the four diapers is a Pampers Active Fit™ size 4diaper commercially available in Germany in June 2012 to which atransverse separator sheet is attached. Each of the four diaperscomprises a first and a second cuff attachment area wherein the top edgeportion of the separator sheet is attached by pressure bonding to thecrotch region of the elastic cuffs of the diaper. Each of the fourdiapers also comprise one central topsheet attachment area and two sidetopsheet attachment areas wherein the bottom edge portion of theseparator sheet is attached by pressure bonding to the topsheet of thediaper. Each of the four diaper has a longitudinal dimension of 488 mm.

The first and second cuff attachment areas have a rectangular shape witha longitudinal dimension of 15 mm and a lateral dimension of 13 mm andare the inner edge of each of the first and second cuff attachment areasis oriented parallel to the longitudinal centerline Y of the diaper andare mirror images of one another in the longitudinal centerline Y of thediaper, in flat state of the diaper. The central and the two sidetopsheet attachment areas have a rectangular shape oriented parallel tothe lateral centerline X of the diaper. Each of the central and the twoside topsheet attachment areas has a longitudinal dimension of 6 mm anda lateral dimension of 20 mm and are spaced with a lateral dimensionbetween two adjacent topsheet attachment areas of 7.5 mm.

Each of the four diapers is made of a different separator sheet materialas described hereinafter. Each of the separator sheet material isrectangular and has a longitudinal dimension of 85 mm and a transversedimension of 100 mm when laid out flat onto an even horizontal surfacein relaxed, contracted state and is oriented such that the separatorsheet material is extensible in the transverse direction.

Examples 1 to 3

The transverse separator sheets of the diapers of examples 1, 2 and 3are made of the activated trilaminate separator sheet materials shown inTable 1.

The activated trilaminate separator sheet materials, shown in Table 1,are made by adhesive lamination of an extrusion bilaminate (EBL,NW1/A1/B1/A2) to a second nonwoven (NW2), followed by activation torelease the stretch.

EBL useful in the present invention are disclosed in U.S. Pat. No.8,168,853, by Autran, etc., and are made by Clopay Plastic Product ofMason, Ohio. The EBL is made by bringing one nonwoven (NW1) onto afreshly extruded and drawn-down multilayer film (A1/B1/A2) in closecontact to each other at the nip of two compression rolls undercontrolled temperature and pressure conditions to form a bond betweenthe tie layer (A1) of the extruded multilayer film (A1/B1/A2) and thefibers of the nonwoven (NW1).

The EBL comprises a first nonwoven (NW1) and a 15 gsm multilayer filmcomprising a tie layer (A1), an inner layer (B1), and a skin layer (A2).The composition of the film inner layer (B1) for examples 1 and 2 is aweight % blend of 92% Vistamaxx 6102, 1% Ampacet 10562 (process aid) and7% Ampacet 110361 (white masterbatch with 70% TiO₂). The composition ofthe film inner layer (B1) of the EBL of example 3 is a weight % blend of87% Vistamaxx 6102, 5% Inspire Dow 118 PP, 1% Ampacet 10562 and 7%Ampacet 110361. The composition of A1 is compositionally identical to A2and is a weight % blend of 24% Infuse 9107, 75% Elite 5800, and 1%Ampacet 10562.

The first nonwoven (NW1) used in the EBL of examples 1, 2 and 3 is a 15gsm spunbond bicomponent PP/PE (50/50, core/sheath) nonwoven from PegasNonwovens (Czech Republic). The second nonwoven (NW2) adhesivelylaminated to the EBL of examples 1 and 2 is a 20 gsm spunbondbicomponent PP/PE (70/30, core/sheath) nonwoven from Fiberweb(Washougal, Wash.), while in example 3, the second nonwoven (NW2) ismade of the same nonwoven as the first nonwoven (NW1), i.e. a 15 gsmspunbond bicomponent PP/PE (50/50, core/sheath) nonwoven from PegasNonwovens (Czech Republic). Vistamaxx 6102 resin is available fromExxonMobil Chemical Company of Houston, Tex. Ampacet 10562 and 110361are available from Ampacet Corporation of Cincinnati, Ohio. Elite 5800PE and Infuse 9107 resins are available from The Dow Chemical Company ofMidland, Mich.

For examples 1, 2 and 3, the aged roll of EBL is combined with thesecond nonwoven (NW2) using a high speed adhesive lamination process,with the addition of approximately 4.5 gsm of Bostik H2861 adhesive(commercially available from Bostik Inc. of Wauwatosa, Wis.) to theA2-NW2 interface to form a trilaminate. For examples 1 and 3, thelamination is followed by mechanical activation by a ring rollingactivation process. For example 2, the lamination is followed bymechanical activation by High Speed Research Press (HSRP) activation.Lamination and activation details are shown in Table 1.

HSRP activation process is described in U.S. Pat. Nos. 7,062,983 and6,843,134. HSRP activation process refers to the use of aluminum plateswith inter-meshing teeth to selectively stretch portions of thetrilaminate such that the nonwoven layers are broken and/or elongatedand the elastic multilayer film is able to extend and retract withoutbeing unduly encumbered by the nonwoven layers. The activation platesused for the HSRP activation have inter-meshing teeth with a tip radiusof 0.1 mm, a root radius of 0.5 mm and tooth height of 10.15 mm.

TABLE 1 Examples of activated trilaminate separator sheet materialsExamples 1 2 3 Trilaminate Structure = adhesive free bilaminateNW1/A1/B1/A2 + 4.5 gsm H2861 adhesive + NW2 NW1 1¹ 1 1 A1 = A2 Infuse/PEblend³ Infuse/PE blend Infuse/PE blend B1 VM blend-1⁴ VM blend-1⁴ VMblend-2⁵ NW2 2² 2 1 total film basis weight 15 gsm 15 gsm 15 gsmmultilayer film structure A1/B1/A2 A1/B1/A2 A1/B1/A2 Details of adhesivelamination (combining bilaminate + NW) and activation Interface withAdhesive A2-NW2 A2-NW2 A2-NW2 Adhesive type (Bostik) H2861 H2861 H2861Adhesive basis weight (gsm) 4.5 gsm 4.5 gsm 4.5 gsm Nip Gap 0.005″0.005″ 0.005″ lamination line speed (m/sec) 5.4 5.4 6.1 activation typeon line @ 5.4 m/sec HSRP @ 0.3 m/sec with on line @ 6.1 m/sec 250millisecond dwell time activation pitch, inches (mm) 0.100″ (2.54 mm)0.098″ (2.49 mm) 0.100″ (2.54 mm) Depth of engagement, DOE, inches (mm)0.160″ (4.06 mm) 0.220″ (5.59 mm) 0.200″ (5.08 mm) Average Strain ofactivation (%) 240% 364% 318% ¹NW = 1 = 15 gsm (50/50 core/sheath,PP/PE) bicomponent spunbond, produced at Pegas Nonwovens (CzechRepublic). ²NW = 2 = 20 gsm (70/30 core/sheath, PP/PE) bicomponentspunbond, produced at Fiberweb (Washougal, Washington). ³Infuse/PE blend= Infuse 9107 (24%), Elite 5800 PE (75%), Ampacet 10562 (1%) in weight%. ⁴VM blend-1 = Vistamaxx 6102 (92%), Ampacet 10562 (1%), Ampacet110361 (7%) in weight %. ⁵VM blend-2 = Vistamaxx 6102 (87%), Dow 118 PP(5%), Ampacet 10562 (1%), Ampacet 110361 (7%) in weight %.

Example 4

The transverse separator sheet of the diapers of example 4 is made ofthe back ear material of Pampers Active Fit™ diapers commerciallyavailable in Germany in June 2012.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm”.

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it atone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. An infant or adult diaper having a longitudinalcenterline and a lateral centerline perpendicular to the longitudinalcenterline, wherein the diaper comprises a topsheet and a backsheet andpositioned therein between an absorbent core, first and secondlongitudinally extending opposing elastic cuffs on either longitudinalside of the topsheet, the diaper having a crotch region, positioned inbetween a front region and a back region, wherein the diaper comprises atransverse separator sheet made of a separator sheet material, thetransverse separator sheet having a transversely extending top edge andtop edge portion and an opposing transversely extending bottom edge anda bottom edge portion, wherein parts of the top edge portion areattached to the cuffs in the crotch region or front region to form afirst cuff attachment area and a second opposing cuff attachment area,each cuff attachment area having an inner edge towards the longitudinalcenterline of the diaper; and the bottom edge portion is attached to thetopsheet at one or more topsheet attachment areas, and wherein the firstcuff attachment area has a first projected bond length as measuredaccording to the projected bond measurement test method and the secondcuff attachment area has a second projected bond length as measuredaccording to the projected bond measurement test method wherein theaverage of the first and second projected bond lengths is from 1% to 20%of the longitudinal dimension of the crotch region of the diaper, in aflat state of the diaper.
 2. The diaper according to claim 1, whereineach of the first and second elastic cuffs has a longitudinallyextending distal edge, and a minimum transverse dimension between eitherof the longitudinally extending distal edges of a cuff and an inner edgeof the a cuff attachment area thereon is 0 to 15 mm.
 3. The diaperaccording to claim 1, wherein the first and second cuff attachment areasare mirror images of one another about the longitudinal centerline ofthe diaper, in flat state of the diaper.
 4. The diaper according toclaim 1, wherein the inner edge of either of first and second cuffattachment areas forms an angle α of more than 0° with the longitudinalcenterline of the diaper, in the flat state of the diaper.
 5. The diaperaccording to claim 1, wherein the first and second cuff attachment areashave a rectangular shape.
 6. The diaper according to claim 1, whereineach of the one or more topsheet attachment areas has a maximumlongitudinal dimension of from 1% to 10% of the longitudinal dimensionof the crotch region of the diaper.
 7. The diaper according to claim 1,wherein a bonding pattern density of at least one of the topsheetattachment area(s) is more than 20%.
 8. The diaper according to claim 1,wherein the topsheet is an apertured topsheet, wherein each of the oneor more topsheet attachment areas comprises one or more individualbonds, wherein: a. at least one of the topsheet attachment areas has abonding pattern density which is higher than the percentage open area ofthe topsheet measured according to the topsheet effective aperture sizeand percentage open area measurement test method; or b. at least oneindividual bond in at least one of the topsheet attachment areas has abigger size than at least one of the effective apertures of thetopsheet; or c. the bonding pattern of at least one of the topsheetattachment areas does not overlap with the effective aperture pattern ofthe topsheet.
 9. The diaper according to claim 1, wherein the one ormore topsheet attachment areas comprise one central topsheet attachmentarea and two side topsheet attachment areas on either side of thecentral topsheet attachment area.
 10. The diaper according to claim 1,wherein the maximum transverse dimension of the one or more topsheetattachment areas is centered about the longitudinal centerline of thediaper, in flat state of the diaper.
 11. The diaper according to claim1, wherein each of the first and second elastic cuffs has alongitudinally extending distal edge and a maximum transverse dimensionof the one or more topsheet attachment areas is disposed within theminimum transverse dimension between the longitudinally extending distaledges of the first and second elastic cuffs, in flat state of thediaper.
 12. The diaper according to claim 11, wherein the maximumtransverse dimension of the one or more topsheet attachment areas is 50%to 98% of the minimum transverse dimension between the longitudinallyextending distal edges of the first and second elastic cuffs, in flatstate of the diaper.
 13. The diaper according to claim 1, wherein thetransverse separator sheet is elastically extensible in the transversedirection to a strain of at least 0.8, as measured according to thein-process two-cycle hysteresis test.
 14. The diaper according to claim1, wherein the separator sheet material comprises an elastic film, anonwoven sheet material, a laminate of an elastic film and a nonwovensheet material, or comprises one or more elastic bands or strands.